Method of surface micro-texturing with a subtractive agent

ABSTRACT

A method of micro-texturing a substrate surface is disclosed, including printing a maskant on the substrate surface to define exposed surface zones on the substrate surface. The method further includes forming a micro-texture on the substrate surface by removing material from the exposed surface zones, and removing the maskant from the substrate surface.

FIELD

This disclosure relates to systems and methods for micro-texturing asurface. More specifically, the disclosed examples relate to controlledapplication of a subtractive agent to form microstructures on a surface.

INTRODUCTION

Texturing of aerodynamic surfaces for drag reduction, increased lift, orother desirable aerodynamic properties is an ongoing area of research.Potential applications range from golf balls, to surf boards, toairplanes. However, practical fabrication of durable surface texturesremains an obstacle to implementation, particularly for economicallyviable large-scale production. Existing manufacturing methods aretypically slow, costly, and/or produce materials of limited durability.

Riblet microstructures are an example of a drag-reducing surface texturethat has been researched for decades, demonstrated to provide up to a10% reduction in skin friction, but has not yet been implemented oncommercial aircraft due to manufacturing challenges. Riblets are apattern of alternating ridges and grooves, approximately aligned withthe direction of airflow that reduce drag by inhibiting turbulence inthe boundary layer. Sharp, narrow ridges are most effective, and thoughappropriate spacing depends on the expected flow conditions, typicalspacing is on the order of thousandths of an inch (mil) or tens ofmicrometers (μm).

Traditional methods such as machining or grinding are not well suited toprecise manufacturing of such small-scale structures. Current techniquesinclude molding riblets in thin sheets of a material such as a plasticfilm, which are then applied to the aerodynamic surface. However,precise positioning and successful bonding of such sheets over largeareas can be difficult and time-consuming, and the plastic films candegrade under atmospheric conditions.

SUMMARY

The present disclosure provides systems, apparatuses, and methodsrelating to micro-texturing a substrate surface. In some examples, amethod of micro-texturing a substrate surface may include printing amaskant on the substrate surface to define exposed surface zones on thesubstrate surface. The method may further include forming amicro-texture on the substrate surface by removing material from theexposed surface zones, and removing the maskant from the substratesurface.

In some examples, an apparatus for creating a micro-texture on asubstrate surface may include a maskant reservoir, a printer, and acontroller. The printer may include a nozzle assembly configured todispense a maskant from the maskant reservoir onto the substratesurface. The controller may be programmed to move the first nozzleassembly relative to the substrate surface to deposit the maskant on thesubstrates surface in a pattern exposing etching surface regionsconfigured for generating a micro-textured surface on the substratesurface.

In some examples, a method for generating a micro-texture on a substratesurface may include connecting a nozzle to a printer, the nozzle beingconfigured to deposit a maskant onto the substrate surface. The methodmay further include printing the maskant through the nozzle onto thesubstrate surface in a pattern defining locations of peaks in themicro-texture. The method may further include removing material from thesubstrate surface between the locations of the peaks, and removing themaskant from the substrate surface.

Features, functions, and advantages may be achieved independently invarious examples of the present disclosure, or may be combined in yetother examples, further details of which can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an illustrative micro-texture inaccordance with aspects of the present disclosure.

FIG. 2 is a schematic diagram of another illustrative micro-texture.

FIG. 3 is a schematic diagram of an illustrative aircraft includingmicro-textured exterior surfaces.

FIG. 4 is a schematic diagram of an illustrative micro-texturing printerapparatus as described herein.

FIG. 5 is a schematic diagram of another illustrative micro-texturingprinter apparatus as described herein.

FIG. 6 is a schematic diagram of an illustrative substrate surface.

FIG. 7 is a schematic diagram of droplets of a maskant printed onto thesubstrate surface of FIG. 6.

FIG. 8 is a schematic diagram of the maskant droplets cured onto thesubstrate surface of FIG. 6.

FIG. 9 is a schematic diagram of an etchant sprayed onto the substratesurface of FIG. 6.

FIG. 10 is a schematic diagram of the substrate surface of FIG. 6, withmaterial removed.

FIG. 11 is a schematic diagram of a micro-texture formed on thesubstrate surface of FIG. 6, with the maskant removed.

FIG. 12 is a flow chart depicting steps of an illustrative method formicro-texturing a substrate surface according to the present teachings.

FIG. 13 is a flowchart depicting steps of an illustrative aircraftmanufacturing and service method.

FIG. 14 is a schematic diagram of an illustrative aircraft.

DETAILED DESCRIPTION

Various aspects and examples of a method for micro-texturing a surfaceand a related apparatus, are described below and illustrated in theassociated drawings. Unless otherwise specified, a method or apparatusin accordance with the present teachings, and/or its various componentsmay, but are not required to, contain at least one of the structures,components, functionalities, and/or variations described, illustrated,and/or incorporated herein. Furthermore, unless specifically excluded,the process steps, structures, components, functionalities, and/orvariations described, illustrated, and/or incorporated herein inconnection with the present teachings may be included in other similardevices and methods, including being interchangeable between disclosedexamples. The following description of various examples is merelyillustrative in nature and is in no way intended to limit thedisclosure, its application, or uses. Additionally, the advantagesprovided by the examples described below are illustrative in nature andnot all examples provide the same advantages or the same degree ofadvantages.

This Detailed Description includes the following sections, which followimmediately below: (1) Overview; (2) Examples, Components, andAlternatives; (3) Illustrative Combinations and Additional Examples; (4)Advantages, Features, and Benefits; and (5) Conclusion. The Examples,Components, and Alternatives section is further divided into subsectionsA through C, each of which is labeled accordingly.

Overview

In general, a method of micro-texturing a surface in accordance with thepresent teachings may include controlled deposition of a maskingmaterial onto the surface of a substrate. Droplets of the maskingmaterial may be deposited in a pattern over the surface, and asubtractive agent may subsequently be applied to the surface. Themasking material and/or the subtractive agent may be selected such thatthe masking material resists dissolving by the subtractive agent, themasking material is non-reactive with the substrate, the maskingmaterial is non-reactive with the subtractive agent, and/or the maskingmaterial is inert. In some examples, the masking material may be cured,dried, and/or bonded prior to application of the subtractive agent.

The subtractive agent may be allowed to dissolve a portion of thoseareas of the substrate surface not covered by the deposited maskingmaterial. The subtractive agent and dissolved material may then beremoved from the substrate. The mask may be removed from the substrate,for instance by application of a corresponding solvent. The pattern inwhich maskant droplets are deposited, droplet size, and other factorssuch as time elapsed before removal of the subtractive agent may beselected to form a desired micro-texture on the surface of thesubstrate. A method in accordance with the present teachings may also bedescribed as etching and/or chemical milling of a micro-texture into asurface.

A method of micro-texturing a surface in accordance with the presentteachings may be performed at least in part with an inkjet printer, aninkjet style of printer apparatus, and/or a printer assembly including adrop-on-demand printhead. The masking material may be thereby printedonto the surface of the substrate. The inkjet printer or printerassembly may include a robotic assembly. The inkjet printer or printerassembly may include a programmable controller, which may be programmedto deposit the masking material onto a curved surface of the substrate.The inkjet printer or printer assembly may additionally or alternativelyinclude a control system configured to allow real-time control by a userand/or dynamically alter deposition in response to real-time feedbacksuch as sensor data. For example, a control system may alter a volume ofmasking material deposited in response to a difference between ameasured and a programmed surface position.

The substrate may be a top layer of material a manufactured part,component, and/or article, and/or may be a top layer of a material foruse in manufacture of parts, components, and/or articles. The substratemay be a sacrificial portion of a material, may include an additivelymanufactured layer, and/or may include a layer applied to the material.For example, the substrate may include a portion of the aluminum of anaircraft wing skin, may include a paint coating over some or all of acomplete aircraft, and/or may include a polymer cured onto a compositeused in manufacture of aircraft exterior surfaces. A layer may beapplied for the purpose of forming a micro-texture and/or may beintended to serve other functions such as protective coating of thesubstrate. The substrate may include a single material, a combination ofmaterials, and/or may be a composite material.

The subtractive agent may include any chemical and/or combination ofchemicals appropriate to dissolve the substrate. The subtractive agentmay also be referred to as an etchant and/or a chemical milling agent.The subtractive agent may be selected according to the material of thesubstrate which is to be micro-textured. The subtractive agent may alsobe selected for a desired etching strength or potential, and/or adesired viscosity or other hydrodynamic properties. Selection of anappropriate subtractive agent may facilitate creation of a micro-textureon a desired scale and with a desired precision.

The masking material may include any chemical and/or combination ofchemicals appropriate protect the substrate from the subtractive agent.The masking material may also be referred to as a maskant and/or aresist. The masking material may be selected according to the selectedsubtractive agent and/or the substrate which is to be micro-textured.The masking material may also be selected for a desired bondingproperties, cure time, ease of removal, and/or a desired viscosity orother hydrodynamic properties.

A micro-texture may comprise a pattern of micro or nano-scalestructures, which may be referred to as surface features ormicrostructures. A method of micro-texturing a surface in accordancewith the present teachings may also be described as creating surfacefeatures by removing material around selected feature locations, by useof a subtractive agent.

The surface features of a micro-texture may not be visible to the nakedeye. In other words, individual surface features may require use ofmagnification to be optically distinguished. However, the plurality ofsurface features forming a micro-texture may change overall visualproperties of a surface, such as reflectivity. The surface features mayinteract with fluids such as air and water that are incident on or flowover a micro-textured surface, to affect the fluid dynamics of thesurface. FIGS. 1 and 2 show two illustrative micro-textures, which havedesirable fluid dynamic effects. The methods and apparatus describedherein may also be applied to create other micro-textures and/or surfacefeatures that are currently known or are as yet unknown.

FIG. 1 is a diagram of a riblet micro-texture 20, comprising a patternof alternating riblets 22 and grooves 24. The riblets may also bedescribed as ridges, micro-riblets, and/or linear protrusions. As notedabove, when aligned with a direction of airflow, the riblets reduce skinfriction drag by inhibiting lateral turbulence motions near the bottomof the boundary layer of air. The effectiveness of the riblets andextent of the drag reduction depend on properties of the airflow such asthe Reynolds number, and multiple parameters of the riblets. Each riblet22 has a height 26 measured from the bottom of adjacent grooves 24 tothe tip of the riblet, and a tip width 28. Adjacent riblets 22 arespaced by a distance 30. In other words, the width of grooves 24 isdefined by spacing (i.e. distance) 30 between riblet tips.

In the present example, a scalloped riblet shape is depicted, butriblets may have a variety of profiles including triangular and bladeprofiles. Generally, studies of drag reduction for different ribletprofiles and geometries suggest that sharp, narrow riblets are mosteffective. Spacing 30 may be determined according to an expectedReynolds number. For example, a spacing of between 3 and 4 mil orbetween 75 and 100 μm may be effective for a Reynolds number of 1.7,which is typical of flight at Mach number 0.85 at an altitude of 35,000feet. For another example, a spacing selected from a range between 1 and10 mil or between 25 and 250 μm may be effective for flight at manyconventional speeds and altitudes. Height 26 may be determined inrelation to spacing 30. A height of half spacing (i.e. distance) 30 orgreater has been shown to be most effective. For example, height 26 maybe selected from a range of 15 and 20 mil or 35 and 50 μm, for a spacingbetween 3 and 4 mil or between 75 and 100 μm.

Turbulence models for specific surfaces and/or applications may be usedin Computational Fluid Dynamics (CFD) calculations to design effectiveriblet patterns and/or dimensions. Effective riblets parameters may varyover a surface, particularly surfaces having complex curvature. Forexample, in regions away from the leading edge of a surface, greaterriblet spacing 30 may yield improved drag reduction as compared withregions adjacent the leading edge.

FIG. 2 is a diagram of an illustrative artificial lotus micro-texture40, which may also be referred to as a lotus leaf micro-texture and/or alotus leaf surface. The surface of a natural lotus leaf is covered inpapillae approximately 10-20 μm in height and width. Together with a waxcoating, these papillae render the leaf's surface ultrahydrophobic.Water droplets on the surface have a contact angle close to or exceeding150 degrees, minimizing adhesion to the surface. Artificialultrahydrophobic microstructures and nanostructures have been studiedfor a variety of applications, particularly in biotechnology. Suchstructures have also been suggested for anti-fouling and anti-icingapplications on aircraft surfaces.

The artificial lotus micro-texture shown in FIG. 2 includes a pattern ofrounded towers 42 and troughs 44. The texture may be described as havingunitary roughness. Each tower 42 has a height 46 measured from thebottom of adjacent troughs 44 to the peak of the tower. The width oftroughs 44 is defined by a spacing 48 between tower peaks. Generally,minimizing the width of towers 42 and increasing spacing 48 may increasethe contact angle and hydrophobicity of the surface.

FIG. 3 is a diagram of an illustrative aircraft 60, includingdrag-reducing micro-textured surfaces. An exterior skin 62 of theaircraft includes multiple drag-reduction zones 64, which havemicro-texturing such as riblets. Drag-reduction zones 64 cover a largeproportion of exterior skin 62, including wings 66 and fuselage 68.However, some aerodynamically distinct sections of exterior skin 62 suchas leading edges 70 of wings 66 do not include micro-texturing.Appropriate and effective disposition of drag-reduction zones 64 mayform part of the aerodynamic design of aircraft 60.

In the depicted example, aircraft 60 is a commercial jet. Drag-reductionzones 64 may also be used on an exterior skin of other aircraft such ashelicopters or drones, or on exterior surfaces of other vehicles such ascars, trains, or ships. In some examples, ultrahydrophic zones and/orareas having other desired fluid dynamic effects may be used incombination and/or in place of drag-reduction zones 64. In someexamples, micro-textures surfaces produced using the methods orapparatus described herein may be applied to non-vehicle systems such assports equipment, projectiles, and/or any system having surfaces subjectto fluid dynamic effects.

Aspects of a method or apparatus for micro-texturing a surface may beembodied as a computer method, computer system, or computer programproduct. Accordingly, aspects of the method or apparatus may take theform of an entirely hardware example, an entirely software example(including firmware, resident software, micro-code, and the like), or anexample combining software and hardware aspects, all of which maygenerally be referred to herein as a “circuit,” “module,” or “system.”Furthermore, aspects of the method or apparatus may take the form of acomputer program product embodied in a computer-readable medium (ormedia) having computer-readable program code/instructions embodiedthereon.

Any combination of computer-readable media may be utilized.Computer-readable media can be a computer-readable signal medium and/ora computer-readable storage medium. A computer-readable storage mediummay include an electronic, magnetic, optical, electromagnetic, infrared,and/or semiconductor system, apparatus, or device, or any suitablecombination of these. More specific examples of a computer-readablestorage medium may include the following: an electrical connectionhaving one or more wires, a portable computer diskette, a hard disk, arandom access memory (RAM), a read-only memory (ROM), an erasableprogrammable read-only memory (EPROM or Flash memory), an optical fiber,a portable compact disc read-only memory (CD-ROM), an optical storagedevice, a magnetic storage device, and/or any suitable combination ofthese and/or the like. In the context of this disclosure, acomputer-readable storage medium may include any suitablenon-transitory, tangible medium that can contain or store a program foruse by or in connection with an instruction execution system, apparatus,or device.

A computer-readable signal medium may include a propagated data signalwith computer-readable program code embodied therein, for example, inbaseband or as part of a carrier wave. Such a propagated signal may takeany of a variety of forms, including, but not limited to,electro-magnetic, optical, and/or any suitable combination thereof. Acomputer-readable signal medium may include any computer-readable mediumthat is not a computer-readable storage medium and that is capable ofcommunicating, propagating, or transporting a program for use by or inconnection with an instruction execution system, apparatus, or device.

Program code embodied on a computer-readable medium may be transmittedusing any appropriate medium, including but not limited to wireless,wireline, optical fiber cable, RF, and/or the like, and/or any suitablecombination of these.

Computer program code for carrying out operations for aspects of amethod of micro-texturing a surface may be written in one or anycombination of programming languages, including an object-orientedprogramming language such as Java, Smalltalk, C++, and/or the like, andconventional procedural programming languages, such as C. Mobile appsmay be developed using any suitable language, including those previouslymentioned, as well as Objective-C, Swift, C#, HTML5, and the like. Theprogram code may execute entirely on a user's computer, partly on theuser's computer, as a stand-alone software package, partly on the user'scomputer and partly on a remote computer, or entirely on the remotecomputer or server. In the latter scenario, the remote computer may beconnected to the user's computer through any type of network, includinga local area network (LAN) or a wide area network (WAN), and/or theconnection may be made to an external computer (for example, through theInternet using an Internet Service Provider).

Aspects of a method of micro-texturing a surface are described belowwith reference to flowchart illustrations and/or block diagrams ofmethods, apparatuses, systems, and/or computer program products. Eachblock and/or combination of blocks in a flowchart and/or block diagrammay be implemented by computer program instructions. The computerprogram instructions may be provided to a processor of a general purposecomputer, special purpose computer, or other programmable dataprocessing apparatus to produce a machine, such that the instructions,which execute via the processor of the computer or other programmabledata processing apparatus, create means for implementing thefunctions/acts specified in the flowchart and/or block diagram block(s).In some examples, machine-readable instructions may be programmed onto aprogrammable logic device, such as a field programmable gate array(FPGA) or a programmable logic controller (PLC).

These computer program instructions can also be stored in acomputer-readable medium that can direct a computer, other programmabledata processing apparatus, and/or other device to function in aparticular manner, such that the instructions stored in thecomputer-readable medium produce an article of manufacture includinginstructions which implement the function/act specified in the flowchartand/or block diagram block(s).

The computer program instructions can also be loaded onto a computer,other programmable data processing apparatus, and/or other device tocause a series of operational steps to be performed on the device toproduce a computer-implemented process such that the instructions whichexecute on the computer or other programmable apparatus provideprocesses for implementing the functions/acts specified in the flowchartand/or block diagram block(s).

Any flowchart and/or block diagram in the drawings is intended toillustrate the architecture, functionality, and/or operation of possibleimplementations of systems, methods, and computer program productsaccording to aspects of the method of micro-texturing a surface. In thisregard, each block may represent a module, segment, or portion of code,which comprises one or more executable instructions for implementing thespecified logical function(s). In some implementations, the functionsnoted in the block may occur out of the order noted in the drawings. Forexample, two blocks shown in succession may, in fact, be executedsubstantially concurrently, or the blocks may sometimes be executed inthe reverse order, depending upon the functionality involved. Each blockand/or combination of blocks may be implemented by special purposehardware-based systems (or combinations of special purpose hardware andcomputer instructions) that perform the specified functions or acts.

EXAMPLES, COMPONENTS, AND ALTERNATIVES

The following sections describe selected aspects of exemplary methods ofmicro-texturing a surface with a subtractive agent as well as relatedsystems and/or apparatus. The examples in these sections are intendedfor illustration and should not be interpreted as limiting the entirescope of the present disclosure. Each section may include one or moredistinct examples, and/or contextual or related information, function,and/or structure.

A. Illustrative Micro-Texturing Printer Apparatus

As shown in FIGS. 4 and 5, this section describes two illustrativeapparatus for micro-texturing a surface. Micro-texturing apparatus 100,shown in FIG. 4, may be appropriate for use with surfaces on objects ormaterials of limited dimensions. That is, apparatus 100 may beappropriate for use with a workpiece 102 that can be supported on and/orfed over a printing platform 104. Micro-texturing apparatus 200, shownin FIG. 5, may be appropriate for use on large or complex surfaces, andmay be configured for mobility relative to a large workpiece 202.

Micro-texturing apparatus 100 includes a printer 106, with a gantry 108disposed over printing platform 104. A nozzle assembly 110 is mounted ongantry 108. The gantry includes one or more x-axis motors 112 and z-axismotors 114, and printing platform 104 includes one or more y-axis motors116. Together gantry 108 and printing platform 104 provide control ofthe positioning of nozzle assembly 110 relative to workpiece 102. Insome examples, gantry 108 may further include rotational actuators, toallow control of the orientation of nozzle assembly 110 relative toworkpiece 102. The depicted example may be effective for workpieceshaving a flat surface, while apparatus including orientation control mayallow micro-texturing of curved and/or complex surfaces.

Nozzle assembly 110 includes an inkjet printhead with one or morenozzles. Printer 106 may therefore be referred to as an inkjet printer.The inkjet printhead may operate on thermal bubble, piezoelectric,and/or any effective principles. In some examples, nozzle assembly 110may include other mechanisms appropriate for controlled deposition offluid droplets. Nozzle assembly 110 is supplied with a maskant fluid 118from a cartridge or reservoir 120. The reservoir and nozzle assembly areeach comprised and/or lined with material appropriate for transport ofmaskant fluid 118.

Micro-texturing apparatus 100 further includes a controller 122 and apower supply 124. Controller 122 may be a standard controller adaptedfrom an additive manufacturing printer and/or an ink printer. Controller122 may also be specifically designed for control of printer 106.

Controller 122 may be a programmable logic controller system (alsoreferred to as a PLC system) suitable for implementing aspects ofmicro-texturing controls in accordance with aspects of the presentdisclosure. The controller may be an example of a data processingsystem. Controller 122 includes a central processing unit (CPU) 126, anda memory 128 for storing instructions and parameters necessary to carryout relevant automation tasks.

Controller 122 includes an input module 130 in receiving communicationwith one or more input devices/sensors, and an output module 132 inoutgoing communication with one or more output devices. Input module 130may convert analog signals from input devices/sensors into digitaland/or logic signals that the controller can use. Upon evaluating theinput(s), along with known output states and stored program parametersand instructions, CPU 126 may execute one or more predetermined commandsto control one or more output devices, such as nozzle assembly 110and/or motors 112, 114, 116. Output module 132 may convert controlsignals from CPU 126 into digital or analog signals which may be used tocontrol the various output devices.

Input and output modules 130, 132 may also allow for input and output ofdata with other devices that may be connected to controller 122. Forexample, input module 130 may provide a connection for temperature orpressure measurements, nozzle status, etchant reservoir level status,other suitable input device. Output module 132 may send output to anactuator, indicator, motor controller, machine, display, and/or anyother suitable output device.

A programming device may interface with controller 122 to facilitate theinput of instructions and settings and/or to monitor printer operation.Programming devices may include, for example, a handheld computer orpersonal computer. In the present example, controller 122 is connectedto a desktop computer 134 via hardwired connection such as a UniversalSerial Bus (USB) connection. The controller may be configured to receiveinstructions from a program running on computer 134, such as a printerdriver. In some examples, micro-texturing apparatus 100 may includesoftware executable on a computer to generate instructions for a printerdriver and/or controller 122.

Printer 106 may additionally or alternatively include a human machineinterface (HMI) in communication with controller 122. The HMI mayfacilitate a user-friendly and interactive interface with the printerprocesses and controls. The HMI may also assist an operator indetermining printer conditions, in changing printer settings, displayingfaults, and/or making real-time alterations to the printing processesbased on measured or observed results. An HMI and/or programming devicemay provide for communications with other data processing systems ordevices, e.g., through the use of physical and/or wirelesscommunications links.

Printer 106 is configured to print maskant fluid 118 onto a surface 136of workpiece 102. Printing may include dispensing droplets of maskantfluid 118 from reservoir 120 through nozzle assembly 110 onto surface136 in a pattern that defines exposed surface zones corresponding to amicro-texture. Controller 122 is programmed to move nozzle assembly 110relative to surface 136, using motors 112, 114, 116. As noted above,controller 122 may be programmed using an HMI and/or by transmittinginstructions from a programming device such as computer 134. Programmingof controller 122 may also be referred to as programming of printer 106and/or micro-texturing apparatus 100.

In some examples, printer 106 may be programmed to print a patternconfigured to generate riblets on surface 136. In such examples, nozzleassembly 110 may be configured to dispense droplets of maskant fluid 118of a size configured to generate riblets 22 (see FIG. 1) with a tipwidth 28 in a range of 1 to 10 μm. Printer 106 may be configured and/orprogrammed to generate riblets 22 of any desired dimensions. In someexamples, printer 106 may be programmed to print a pattern configured togenerate an artificial lotus leaf structure on surface 136.

In some examples, micro-texturing apparatus 100 may further includeand/or be connected with sensors and/or other data systems configured toprovide and/or evaluate data related to the printing processes. Forexample, the micro-texturing apparatus may include a camera to captureimages of the substrate surface during and/or subsequent to depositionof maskant fluid 118. The images may be analyzed by controller 122and/or connected computer 134 to evaluate the area and pattern coveredby the deposited maskant fluid. Instructions stored on controller 122 orreceived from computer 134 may initiate additional printing processesbased on the evaluation. In some examples, collected data, data analysisand/or evaluations may be stored for later review. Such real-timefeedback and stored information may allow immediate and eventualimprovements in manufacturing quality.

In some examples micro-texturing apparatus 100 may further includeequipment configured to aid performance of further steps of a method ofmicro-texturing a surface, as described herein. For example, apparatus100 may include a nozzle assembly and/or reservoir for use with anetchant fluid. For another example, apparatus 100 may include a sprayerfor uniform delivery of fluids such as etchants, solvents, or water oversurface 136. For another example, apparatus 100 may allow printingplatform 104 to be submerged into a bath of fluid such as an etchant,solvent, or a cleanser such as water.

As shown in FIG. 5, micro-texturing apparatus 200 includes a roboticsystem with a first robotic arm 204 and a second robotic arm 206. Eachrobotic arm 204, 206 includes a nozzle assembly. In the present example,first robotic arm 204 includes a maskant nozzle assembly 210 and secondrobotic arm 206 includes an etchant nozzle assembly 212. Maskant nozzleassembly 210 is configured to dispense droplets of a maskant fluid suchas a neoprene, a copolymer, and/or a wax. Etchant nozzle assembly 212 isconfigured to dispense droplets of an etchant fluid such as an acid, aketone, a solvent, and/or a caustic. Each nozzle assembly may include aninkjet printhead and one or more nozzles. Nozzle assemblies 210 and 212may also be described as pint engines mounted as end-effectors onrobotic arms 204 and 206.

First robotic arm 204 and second robotic arm 206 may each include aseparate controller or may be connected to a shared controller. Thecontroller or controllers may be programmable logic controllers, asdescribed in reference to controller 122 of micro-texturing apparatus100, above. In some examples, the robotic system may include actuatorsother than arms, may include a single robotic arm supporting multiplenozzles and/or other end effectors, may include an automated gantry,and/or may include any effective moveable supports for the nozzleassemblies.

In the present example, each robotic arm 204, 206 is a six-axisindustrial robot. In other words, each arm is articulated to have sixdegrees of freedom and can rotate around six distinct axes. Apparatus200 may include any robotic arms and/or systems providing sufficientrange of motion to address a selected surface of a workpiece. Thesix-axis robots of the present example may provide a greatest range ofmotion, allowing micro-texturing apparatus 200 to be used with a widestvariety of surface and workpiece geometries. For micro-texturing methodsthat do not include application of a maskant, micro-texturing apparatus200 may include only second robotic arm 206.

In the depicted example, workpiece 202 is a section of an aircraft wing,and an upper flight surface 208 is shown partway through amicro-texturing process. In some examples, workpiece 202 may include asheet of flexible material unwound from a roll of composite material. Insome examples, workpiece 202 may comprise a portion of an assembledaircraft, and micro-texturing apparatus 200 may be positioned adjacentthe aircraft. Workpiece 202 may be flat, may have a curvature in asingle direction as depicted in FIG. 5, may have complex curvature thatis heterogenous over the surface, and/or may have any geometry.

Workpiece 202 may be supported on a work surface, by a portion ofmicro-texturing apparatus 200, and/or may be self-supporting.Micro-texturing apparatus 200 may be mobile, and robotic arms 204, 206may be repositionable relative to workpiece 202. The robotic arms mayfurther be repositionable relative to one another. In some examples,micro-texturing apparatus 200 may include a support system appropriateto translate and/or rotate workpiece 202 relative to robotic arms 204,206. For example, micro-texturing apparatus 200 may be configured torotate a cylindrical workpiece, to allow access to all areas of theexterior surface by first nozzle assembly 210 and second nozzle assembly212.

Robotic arm 204 is programmed to print maskant fluid onto flight surface208 in a pattern 214. The pattern may define a plurality of exposedsurface zones 216, which may also be referred to as etching surfaceregions. Pattern 214 may correspond to the locations of peaks in amicro-texture. In the depicted example, pattern 214 includes a pluralityof parallel lines corresponding to the peaks of a plurality of riblets.Robotic arm 206 is programmed to print etchant onto exposed surfacezones 216 of flight surface 208. In FIG. 5, surface 208 is shown with acompleted pattern 214 of maskant and etchant printed onto three ofexposed surface zones 216.

B. Illustrative Method of Micro-Texturing with a Maskant

This section describes steps of an illustrative method formicro-texturing a substrate surface; see FIGS. 6-12. Aspects ofmicro-texturing printing apparatus described above may be utilized inthe method steps described below. Where appropriate, reference may bemade to components and systems that may be used in carrying out eachstep. These references are for illustration, and are not intended tolimit the possible ways of carrying out any particular step of themethod.

FIG. 12 is a flowchart illustrating steps performed in an illustrativemethod 300, and may not recite the complete process or all steps of themethod. Although various steps of method 300 are described below anddepicted in FIG. 12, the steps need not necessarily all be performed,and in some cases may be performed simultaneously or in a differentorder than the order shown.

At step 302, the method includes printing a maskant onto a substratesurface. The substrate may include any workpiece and/or material onwhich micro-texturing is desired. FIG. 6 is a schematic diagram of anillustrative substrate 320. The substrate includes an upper layer 322having a top surface 324, and a lower layer 326. Upper layer 322 may bedescribed as a sacrificial layer, and may be selected and/or configuredfor forming surface features of a micro-texture.

Substrate 320 may be a discrete section of material and/or may be aportion of a larger workpiece. For example, the substrate may be a sheetof composite or may be a section of an aircraft wing skin. In FIG. 6,top surface 324 is shown as flat. Substrate 320 and/or top surface 324may alternatively or additionally be curved, stepped, and/or have anydesired geometry. Substrate 320 may include a single material, may be acomposite, and/or may include layers of different materials.

Upper layer 322 and lower layer 326 may be produced together and/or theupper layer may be applied to the lower layer. For example, upper layer322 and lower layer 326 may comprise a solid block of aluminum alloy.For another example, upper layer 322 and lower layer 326 may eachcomprise an aluminum alloy, with the upper layer having been applied tothe lower layer by an additive manufacturing technique such as DirectMetal Laser Sintering (DMLS). For another example, upper layer 322 maybe a cured polymer top-coat, applied to an aluminum alloy lower layer326. For another example, upper layer 322 and lower layer 326 maycomprise a composite material having a polymer matrix material andreinforcing fibers, the upper layer including only matrix material andthe lower layer including both matrix material and reinforcing fibers.

Substep 303 of step 302 includes installing a maskant dispensing nozzleon a printer. For example, one or more nozzles configured for use with aselected maskant fluid may be installed into the printhead of adirect-to-shape (DTS) printer. In some examples, an inkjet nozzle may beinstalled onto another type of printer. For example one or moreDrop-On-Demand inkjet nozzles may be installed on the printhead of aFused Deposition Modeling (FDM) printer, along with a maskant reservoir.Substep 303 may further include any necessary modifications to allowinkjet printing of the maskant.

The printer may be part of a printing apparatus such as micro-texturingapparatus 100 or 200. A printing apparatus may be configuredspecifically for use in method 300, and/or a generic printing apparatusmay be used. A printing apparatus may be selected and/or designed toeffectively print on substrate 320.

Substep 304 of step 302 includes depositing the maskant from the nozzlein a pattern defining exposed zones and peak locations. The maskant maybe deposited to form a pattern selected according to a desiredmicro-texture. A pattern may be selected to form a riblet micro-texture,to form an artificial lotus leaf micro-texture, and/or any desiredmicro-texture.

The maskant may be selected according the material of the substrateand/or the additive layer. In other words, the maskant may be selectedto be non-reactive with the material of the surface and to providesufficient adherence to the surface. The maskant may also be selectedaccording to an intended etchant. In other words, the maskant may beselected to be non-reactive with the etchant, and/or to resistdissolving by the etchant. The maskant may be selected according todesired properties such as low viscosity, quick cure times, and/orstrong adhesion. Examples of appropriate maskants includeisobutylene-isoprene copolymers such as butyl rubber, chloropreneelastomers such as Neoprene, resins, waxes, and wax-like materials.

In the example depicted in FIG. 7, droplets 330 of a maskant 328 aredropped onto surface 324 in a regularly spaced pattern as a printheadprogresses in a direction indicated by arrow 332. The completed patternis depicted in FIG. 8. One traversal of the printhead across surface 324may referred to as a pass. The printhead may repeatedly travel acrosssurface 324, in multiple passes. On each pass, droplets 330 may bedropped in corresponding locations, in order to form a plurality ofregularly spaced lines of maskant 328 on the surface. In some examples,droplets 330 may be dropped without spacing in each pass, to form acontinuous line. In such examples, the passes may be spaced on surface324 to similarly form a plurality of spaced lines of maskant 328 on thesurface.

Such a pattern may be selected to form a riblet micro-texture. Eachcontinuous line of maskant 328 may define a peak location of a riblet 22(see FIG. 1). Exposed zones 334 may be defined between the lines,corresponding to a groove 24 between riblets 22. The pattern may beconfigured to achieve desired parameters of the surface features of themicro-texture. For example, the width of exposed zones 334 may beselected to create riblets having a spacing in a range of 70 to 100 μm,in a range of 10 to 250 μm, or any desired range. To achieve a desiredriblet tip width, the size of droplets 330 may be selected. Selecting adroplet size may include selecting a viscosity of maskant 328,configuring one or more nozzles of a printhead, and/or programming aprinting apparatus. To achieve a desired micro-texture, a pattern may bedesigned according to known properties of upper layer 322 and/or maskant328. For example, droplet spacing may be selected based on a desiredriblet spacing and/or based on an expected spread of droplets 330 ofsurface 324.

Step 305 includes curing and/or bonding the maskant. The maskant may becured by application of ultra-violet light, by application of heat, bydrying, by allowing time to elapse, and/or by any effective method. Themaskant may be cured such that effective bonding of the maskant to thesubstrate surface is achieved.

At step 306, method 300 includes forming a micro-texture by removingmaterial from the surface. Substep 307 includes applying an etchant tothe surface. The etchant may be applied in any effective manner.Optional substep 308 includes printing the etchant onto the exposedzones. Similarly to step 302, a printer and/or printing apparatus may beused to perform optional substep 308. Etchant droplets may be printeduniformly over the surface, and/or may be printed according to a patternof the maskant. For example, the etchant droplets may be deposited tocover exposed surface zones 334 as shown in FIG. 8. Printing the etchantmay include dispensing droplets of the etchant from an inkjet nozzleonto the surface. Optional substep 309 includes dipping the surface inan etchant bath. Chemical milling techniques may be used to performoptional substep 309.

Optional substep 310 includes spraying the etchant over the exposedzones. In the example depicted in the schematic diagram of FIG. 9, anetchant 336 is sprayed uniformly over surface 324, including exposedzones 334. The etchant may be sprayed by a printing apparatus used toperform step 302 of method 300, or may be sprayed manually, and/or maybe sprayed in any effective manner.

The etchant used in substep 307 may be selected to correspond to thematerial of the substrate. In the example depicted in FIG. 9, etchant336 is selected to correspond to upper layer 322 of substrate 320. Inother words, etchant 336 may be a fluid chosen to effectively dissolvethe material or materials of upper layer 322. For instance, in exampleswhere upper layer 322 comprises aluminum, etchant 336 may be Keller'sreagent or a solution of sodium hydroxide. Examples of appropriateetchants include acids such as sulfuric acid, ketones such as acetone,caustics such as sodium hydroxide, or other solvents such as alcohol.Etchant 336 may be a solution and may have a concentration selected toproduce a desired etching strength and/or speed on upper layer 322.

Once etchant 336 is applied to surface 324, time may be allowed toelapse before performing further steps. The time to elapse may be chosenaccording to a desired volume of material to be dissolved by theetchant. For example, a waiting period may be selected such thatsufficient volume of material is dissolved to create riblets havingheights in a range of 10 to 15 μm, in a range of 1 to 50 μm, or anydesired range. For another example, a waiting period may be selectedsuch that material is dissolved down to an interface between upper layer322 and lower layer 326.

Substep 311 of step 306 includes removing the etchant. Removing etchant336 may also remove material dissolved in the etchant. Etchant 336 maybe removed by washing substrate 320, or by any effective method. Forexample, water may be sprayed uniformly over surface 324 and/orsubstrate 320 may be submerged in a water bath. In some examples,substrate 320 may be evaluated prior to proceeding with the method. Forexample, an operator or technician may inspect the substrate under amicroscope and/or a micro-texturing apparatus may capture an image ofthe substrate surface. The operator, micro-texturing apparatus, and/or adata processing system may evaluate measurements or other data. Based onthe evaluation, substep 307 may be repeated prior to proceeding to step312 of the method.

Step 312 of the method includes removing the maskant. An appropriatemethod of removing the maskant may be selected according to the maskantand the substrate material. For example, optional step 313 includesdipping surface 324 of substrate 320 in a bath of solvent that dissolvesmaskant 328 but is non-reactive with the material of upper layer 322.Maskant 328 may be removed by the same apparatus as was used to applythe maskant, by another apparatus, and/or by hand. Removing maskant 328may leave a micro-texture formed in upper layer 322, as shown in FIG.11. In the depicted example, method 300 has been used to form scallopedriblets in upper layer 322 of substrate 320. The scalloped riblets mayalso be described as formed in top surface 324.

Either optional step 314 or 316 may be performed, depending on thepattern in which the maskant was applied. Optional step 314 includescreating riblets, or a riblet micro-texture. Optional step 315 includescreating artificial lotus leaf structures, or a lotus leafmicro-texture. The micro-texture may be determined in step 302,according to the selected pattern. The formed micro-texture may berevealed once the etchant and maskant have been removed.

C. Illustrative Aircraft and Associated Method

Examples disclosed herein may be described in the context of anillustrative aircraft manufacturing and service method 400 (see FIG. 13)and an illustrative aircraft 500 (see FIG. 14). Method 400 includes aplurality of processes, stages, or phases. During pre-production, method400 may include a specification and design phase 404 of aircraft 500 anda material procurement phase 406. During production, a component andsubassembly manufacturing phase 408 and a system integration phase 410of aircraft 500 may take place. Thereafter, aircraft 500 may go througha certification and delivery phase 412 to be placed into in-servicephase 414. While in service (e.g., by an operator), aircraft 500 may bescheduled for routine maintenance and service 416 (which may alsoinclude modification, reconfiguration, refurbishment, and so on of oneor more systems of aircraft 500). While the examples described hereinrelate generally to operational use during in-service phase 414 ofaircraft 500, they may be practiced at other stages of method 400.

Each of the processes of method 400 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may include,without limitation, any number of aircraft manufacturers andmajor-system subcontractors; a third party may include, withoutlimitation, any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

As shown in FIG. 14, aircraft 500 produced by illustrative method 400may include a frame 502 surrounding an interior 506 and covered by askin 508. The skin may include one or more micro-textured surface zone.The aircraft may further include a plurality of systems 504, such as oneor more of a propulsion system, an electrical system, a hydraulicsystem, and an environmental system. Each system may comprise varioussubsystems, such as controllers, processors, actuators, effectors,motors, generators, etc., depending on the functionality involved. Anynumber of other systems may be included. Although an aerospace exampleis shown, the principles disclosed herein may be applied to otherindustries, such as the automotive industry, rail transport industry,and nautical engineering industry. Accordingly, in addition to aircraft500, the principles disclosed herein may apply to other vehicles, e.g.,land vehicles, marine vehicles, etc.

Apparatuses and methods shown or described herein may be employed duringany one or more of the stages of the manufacturing and service method400. For example, components or subassemblies corresponding to componentand subassembly manufacturing phase 408 may be fabricated ormanufactured in a manner similar to components or subassemblies producedwhile aircraft 500 is operating during in-service phase 414. Also, oneor more examples of the apparatuses, methods, or combinations thereofmay be utilized during production phases 408 and 410, for example, bysubstantially expediting assembly of or reducing the cost of aircraft500. Similarly, one or more examples of the apparatus or methodrealizations, or a combination thereof, may be utilized, for example andwithout limitation, while aircraft 500 is at in-service phase 414 and/orduring maintenance and service phase 416.

ILLUSTRATIVE COMBINATIONS AND ADDITIONAL EXAMPLES

This section describes additional aspects and features of methods andapparatus for micro-texturing a surface, presented without limitation asa series of paragraphs, some or all of which may be alphanumericallydesignated for clarity and efficiency. Each of these paragraphs can becombined with one or more other paragraphs, and/or with disclosure fromelsewhere in this application, in any suitable manner. Some of theparagraphs below expressly refer to and further limit other paragraphs,providing without limitation examples of some of the suitablecombinations.

A. A method of micro-texturing a substrate surface, comprising:

printing a maskant on a substrate surface to define exposed surfacezones on the substrate surface,

forming a micro-texture on the substrate surface by removing materialfrom the exposed surface zones, and removing the maskant from thesubstrate surface.

A1. The method of A, wherein the step of removing material includesdipping the substrate surface in an etchant bath.

A2. The method of A or A1, wherein the step of removing materialincludes spraying an etchant over the exposed surface zones.

A3. The method of any of A-A2, wherein troughs between micro-riblets areformed in the exposed surface zones.

A4. The method of any of A-A3, wherein the forming step includescreating a lotus leaf micro-texture on the substrate surface.

A5. The method of any of A-A4, wherein the step of removing materialincludes depositing an etchant on the substrate surface, and removingthe etchant from the substrate surface.

A6. The method of A5, wherein the etchant is selected from a groupconsisting of: acids, ketones, solvents, and caustics.

A7. The method of A5, wherein the step of depositing the etchantincludes printing the etchant on to the exposed surface zones.

A8. The method of A7, wherein the etchant is also printed on themaskant.

A9. The method of any of A-A8, wherein the step of removing the maskantincludes dipping the substrate surface in a solvent bath.

A10. The method of any of A-A9, further comprising the step of:

curing and bonding the maskant to the substrate surface prior to theforming step.

A11. The method of any of A-A10, wherein the maskant is selected from agroup consisting of: neoprene, copolymers, and wax.

A12. The method of any of A-A11, wherein the substrate surface forms anexterior surface of an aircraft.

A13. The method of any of A-A12, wherein the substrate surface iscurved.

A14. The method of any of A-A13, wherein the substrate is comprised of acomposite material.

A15. The method of any of A-A14, wherein the micro-texture is configuredto exhibit a desired fluid dynamic effect.

A16. The method of A15, wherein the micro-texture is configured toexhibit a desired aerodynamic effect.

A17. The method of A15 or A16, wherein the micro-texture is configuredto exhibit a desired hydrodynamic effect.

B. An apparatus for creating a micro-texture on a substrate surface,comprising:

a maskant reservoir,

a printer including a first nozzle assembly configured to dispense amaskant from the maskant reservoir on to the substrate surface, and

a controller programmed to move the first nozzle assembly relative tothe substrate surface to deposit the maskant on the substrate surface ina pattern exposing etching surface regions configured for generating amicro-textured surface on the substrate surface.

B1. The apparatus of B, wherein the etching surface regions definelocations for spaces between micro-riblets.

B2. The apparatus of B or B1, wherein the controller is programmed tomove the first nozzle assembly relative to the substrate surface todefine locations of adjacent micro-riblets spaced by a distance in arange of about 70-100 microns.

B3. The apparatus of any of B-B2, wherein the etching surface regionsdefine a lotus leaf micro-texture on the substrate surface.

B4. The apparatus of any of B-B3, further comprising:

a second nozzle assembly, wherein the controller is programmed to movethe second nozzle assembly relative to the substrate surface to depositan etchant on the substrate surface.

B5. The apparatus of B4, wherein the etchant is selected from a groupconsisting of: acids, ketones, solvents, and caustics.

B6. The apparatus of B5, wherein the controller is programmed to movethe second nozzle assembly to deposit the etchant for generatingmicro-riblets having heights in a range of about 15-50 microns.

B7. The apparatus of any of B-B6, wherein the first nozzle assembly iscarried by a six-axis robotic apparatus.

B8. The apparatus of any of B-B7, wherein the printer is an inkjetprinter.

B9. The apparatus of any of B-B8, wherein the first nozzle is configuredto dispense the maskant, the maskant being selected from a groupconsisting of: neoprene, copolymers, and wax.

C. A method for generating a micro-texture on a substrate surface,comprising:

connecting a nozzle to a printer, the nozzle being configured to deposita maskant on to the substrate surface,

printing the maskant through the nozzle on to the substrate surface in apattern defining locations of peaks in the micro-texture,

removing material from the substrate surface between the locations ofpeaks, and removing the maskant from the substrate surface.

C1. The method of C, wherein the peaks comprise micro-riblets.

C2. The method of C or C1, wherein the peaks comprise a portion of alotus leaf micro-structure.

C3. The method of any of C-C2, wherein the micro-texture includesstructure that is too small to be seen by an unaided human eye.

C4. The method of any of C-C3, wherein the micro-texture is configuredto exhibit a desired fluid dynamic effect.

C5. The method of C4, wherein the micro-texture is configured to exhibita desired aerodynamic effect.

C6. The method of C4 or C5, wherein the micro-texture is configured toexhibit a desired hydrodynamic effect.

C7. The method of any of C-C6, wherein the nozzle is mounted on asix-axis robotic apparatus.

ADVANTAGES, FEATURES, AND BENEFITS

The different examples of the methods and apparatus for micro-texturinga surface described herein provide several advantages over knownsolutions for creating a micro-texture. For example, illustrativeexamples described herein allow precise, cost-effective manufacture ofmicro-textured surfaces appropriate for large-scale production.

Additionally, and among other benefits, illustrative examples describedherein allow production of durable micro-textures.

Additionally, and among other benefits, illustrative examples describedherein add limited manual labor to the assembly process for a vehiclesuch as an aircraft.

Additionally, and among other benefits, illustrative examples describedherein allow micro-texturing of curved surfaces and other complexgeometries.

Additionally, and among other benefits, illustrative examples describedherein allow production of micro-textures with improved resistance toshear forces.

No known system or device can perform these functions, particularly withsimple adaptation of existing printer technologies. However, not allexamples described herein provide the same advantages or the same degreeof advantage.

CONCLUSION

The disclosure set forth above may encompass multiple distinct exampleswith independent utility. Although each of these has been disclosed inits preferred form(s), the specific examples thereof as disclosed andillustrated herein are not to be considered in a limiting sense, becausenumerous variations are possible. To the extent that section headingsare used within this disclosure, such headings are for organizationalpurposes only. The subject matter of the disclosure includes all noveland nonobvious combinations and subcombinations of the various elements,features, functions, and/or properties disclosed herein. The followingclaims particularly point out certain combinations and subcombinationsregarded as novel and nonobvious. Other combinations and subcombinationsof features, functions, elements, and/or properties may be claimed inapplications claiming priority from this or a related application. Suchclaims, whether broader, narrower, equal, or different in scope to theoriginal claims, also are regarded as included within the subject matterof the present disclosure.

What is claimed is:
 1. A method of micro-texturing an exterior flightsurface of an aircraft, comprising: designating drag-reduction zones onan exterior skin of a painted aircraft, printing by an inkjet printerhead mounted on a six-axis robotic arm, a maskant on a curved flightsurface in a drag-reduction zone to define exposed surface zones on thecurved flight surface, curing and bonding the maskant to the flightsurface, applying an etchant on to the exposed surface zones, andremoving the maskant by washing the flight surface with one or morefluids formulated to remove the etchant and maskant from the flightsurface.
 2. The method of claim 1, wherein the etchant is selected froma group consisting of: acids, ketones, solvents, and caustics.
 3. Themethod of claim 1, wherein micro-riblets are defined by the printedmaskant and troughs between the micro-riblets are formed in the exposedsurface zones.
 4. The method of claim 1, wherein the maskant is selectedfrom a group consisting of: neoprene, copolymers, and wax.
 5. The methodof claim 1, wherein the applying step includes etching micro-ribletsprimarily in designated drag-reduction zones spaced away from leadingedge airfoil surfaces of the aircraft.
 6. The method of claim 1, whereinthe step of applying an etchant includes selectively printing etchantdroplets onto the exposed surface zones to remove material from theexposed surface zones.
 7. The method of claim 1, wherein the step ofprinting by an inkjet printer includes dispensing maskant droplets froma print head, wherein a size of the maskant droplet defines a spacingbetween the exposed surface zones.
 8. The method of claim 1, wherein theapplying step creates micro-riblets on the exposed surface zones, thestep of printing by an inkjet printer includes dispensing maskantdroplets from the printer head, and a size of the maskant dropletdefines a tip width of the micro-riblets.
 9. The method of claim 8,wherein the tip width of the micro-riblets varies with distance from aleading edge of an airfoil.
 10. The method of claim 9, wherein the tipwidth of the micro-riblets increases with increasing distance from theleading edge of the airfoil.
 11. The method of claim 1, furthercomprising: acquiring data from a sensor directed at a portion of theflight surface after the applying step, analyzing the data to determinean extent of etching.
 12. The method of claim 11, further comprising:adjusting the applying step based on the extent of etching determined inthe analyzing step.
 13. The method of claim 11, wherein the sensorincludes a camera.
 14. A method for generating a micro-texture on anexterior flight surface of an aircraft, comprising: connecting a nozzleto an inkjet printer head mounted on a six-axis robotic arm, the nozzlebeing configured to deposit a maskant on a curved painted exteriorflight surface, printing the maskant through the nozzle onto the curvedpainted exterior flight surface in a pattern defining locations of peaksin the micro-texture, curing and bonding the maskant to the flightsurface, applying an etchant onto the flight surface, and removing themaskant by washing the flight surface with one or more fluids formulatedto remove the etchant and the maskant from the flight surface.
 15. Themethod of claim 14, wherein the etchant is selected from a groupconsisting of: acids, ketones, solvents, and caustics.
 16. The method ofclaim 14, wherein the maskant is selected from a group consisting of:neoprene, copolymers, and wax.
 17. The method of claim 14, wherein thepeaks comprise micro-riblets.
 18. The method of claim 17, wherein a tipwidth of the micro-riblets increases with increasing distance from aleading edge of an airfoil.
 19. The method of claim 14, wherein themicro-texture is configured to exhibit a desired fluid dynamic effect.20. The method of claim 19, wherein the micro-texture is configured toexhibit a desired aerodynamic effect.